Method of preparing warp for manufacturing pile fabric.



P. SABONADIER & E. DEAUBONNE.

METHOD OF PREPARING WARP FOR MANUFACTURING PILE FABRIC.

APPLICATION FILED 3111.26, 1909.

1,024,42 1 Patented Apr. 23, 1912.

3 8HEETB-SHEBT 1.

COLUMBIA PLANOORAPH C0,. WASHINGTON. n. c

P. SABONADIER & E. DEAUBONNE. METHOD or PREPARING WARP FOR MANUPAGTURING PILE FABRIC.

APPLICATION FILED JAN. 26, 1909.

Patented Apr. 23, 1912.

3 SHEETS-SHEET 2.

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f P. SABONADIER & E. DEAUBONNE.

METHOD OF PREPARING WARP FOR MANUFACTURING PILB FABRIC.

APPLICATION FILED JAN. 26, 1909. 1,024,421 I Patented Apr. 23, 1912.

3 SHBETS-SHEET 3.

' TINTTEE TATE PATENT @FFTCE.

PAUL SABONAIJIER, 0F EAUBONNE, AND ETIENNE DEAUBONNE, OF NEUILLY-SUR- SEINE, FRANCE.

METHOD OF PREPARING WARP FOR MANUFACTURING PILE FABRIC.

Specification of Letters Patent.

Application filed January 26, 1909.

Patented Apr. 23, 1912. Serial No. 474,272.

To all whom it may concern:

Be it known that we, PAUL SABONADIER, a citizen of the Republic of France, residing at Eaubonne, Seine-et-Oise, France, and ETIENNE DEa'UBoNNn, a citizen of the Republic of France, residing at Neuilly-sur- Seine, Seine, France, have invented a certain new Method of Preparing WVarp for hifanufacturing Pile Fabrics, of which the following is a specification.

This invention relates primarily to the manufacture of carpets, and particularly to that type of carpet which is generally manufactured in the following manner: On a web which constitutes the ground of the carpet and which is stretched in the machine is arranged a series of piles, these series being disposed transversely (in the direction of the weft) the said series of piles are stuffed into the web by a stuffing device, after which the web is moved forward (in the direction of the warp) to a slight extent, and the same operation is repeated until all of the piles have been stuffed into the web. The improved process, in the other hand, comprehends the arrangement at equidistant intervals of a series of piles on a band of suitable material, as, for instance, the socalled Cingalette muslin; a predetermined number of these bands, with the piles fixed to them, are then disposed longitudinally (in the direction of the warp) on the web, so that the piles of each band will constitute, with the corresponding piles of the other bands, a series of separate rows of piles disposed transversely (in the direction of the weft). Thus after each forward movement of the web in the machine a new row of piles is brought into position with relation to the stuffing device. The disposition of the piles on the Cingalette bands obviates the necessity for the preparation of a new longitudinal series of piles after each operation of the stufling device. On a beam are wound side by side a series of bands of Cingalette muslin, after which the whole is so arranged as to unwind the bands simultaneously by an intermittent movement from the said beam, and to wind them, still side by side, on a second beam situated at a certain distance from the first beam, the intervals of the said intermittent movements being utilized for securing one after another the various piles comprised in the successive picks corresponding to each of the said series of wefts along the bands and in series corresponding to the wefts of the pattern.

Various means can be used for securing the various piles along the bands. The best method seems to be to insert the various piles which are to form one and the same warp one after another into the bend of the same band, this being effected by means of the devices hereinafter described, one of the constructions of which is shown diagrammatically in the accompanying drawings.

Figure 1 of the said drawings is a side elevation of a machine in which certain of the above mentioned devices are combined; Fig. 2 is a longitudinal vertical sectional view thereof; Figs. 3, 4i and 5 are fragment front elevations, respectively, on an enlarged scale of the band straightening device, one of the tightening combs or reeds, and one of the beating-up devices comprised in the said machine; Figs. 6, 7 and 8 are, respectively, a side elevation, a front elevation, and a top plan view, with some parts removed, also on an enlarged scale, of the terminal hook with which each arm of the conveyer element is provided.

In said drawings, a indicates the first or unwinding beam above mentioned, on which beam, when the invention is carried out in the manner under consideration, a series of bands 5 are wound side by side, said bands being folded longitudinally upon themselves. These bands are subsequently wound in the same manner on a second beam, indicated by the character 0. A series of long spools cl, the number of which is equal to that of the successive picks or wefts which the pattern comprises, are mounted on a chain 6Z1 passing over one or more sprocket wheels d and forming an endless chain in case of a pattern with repetitions. Each of the said spools (Z is constituted by a series of separate spools arranged side by side, each of which spools carries a thread of the color of that of that part of the pattern to which it corresponds; the end 6 of each of the threads projects from a small tube through which it is passed. The means for straightening the bands comprise a series of beveled rollers f and a toothed reed g, (Figs. 2 and 3), said reed having one more tooth than the number of rollers employed. The spools (Z are detached from the chain (Z by a two-armed conveyer h which seizes themv in turn and brings them into position so that the projecting ends 6 of all of the threads enter the spaces between the two walls of the VS formed by the bands 6 as the latter pass beyond the reed g, after which the said conveyer returns the spools to the chain d, a short end of each of the threads having been first cut off. A first tightening reed is provided, formed by a series of pairs of elastic teeth 2', the number of such pairs being the same as that of the teeth of the straightening reed g. The ends of each pair of these teeth constitute a V- shaped gripper, into each of which passes one of the said bands, (see Figs. 2 and at). This reed, to which is adjoined a vertically reciprocating evener 2' having the same number of teeth as the straightening reed g, is arranged at the very point where the ends I; of the threads are brought at the first downward movement of the conveyer, the said ends being gripped between the teeth 2', owing to the rising of the evener 2' which takes place immediately after the completion of the said first downward movement of the conveyer. A knife 7', preferably arranged for horizontal reciprocating movement, which acts shortly after the tightening reed 1' becomes operative, is then operated at the moment when a certain predetermined length of thread, equal in reality to the length of the pieces or sections intended to form the pile of the velvet), has been unwound from the spool cl carried by the conveyer, owing to the slight initial backward movement of the latter. It is only after the operation of this knife that the spool d in question is brought upward by the conveyer and back to the chain al The first beating-up device consists of a fixed toothed 70, (Figs. 2 and 5), and of a vertically reciprocating body 7: provided with blades, preferably sub-divided longitudinally as shown in Fig. 2; the body has the same number of blades as the reed g has teeth, and the reed 76 has one more tooth than the latter reed. The said blades force the various pieces of thread into proper position longitudinally at the bottom of the Vs formed by the bands Z).

A liquid container Z constitutes the moistening device, said container being areferably heated by a rack-like heater Z provided with as many wicks Z as the reed is has teeth, these wicks being spaced apart to form tracks for the passage of the bands therebetween. A second beating-up device m m is provided similar to the first, which acts on the threads and the bands as they emerge from the moistening device. Two reeds 0 and (1 preferably constitute the second tightening reed, said reeds being each similar to the reed i and having juxtaposed eveners 0 and g operating in conjunction therewith. This second tightening reed is preferably heated, for instance, by a device similar to the heater Z The means for drawing or pulling the bands is advantageously constituted by a cylinder 1" provided with points, on which cylinder the bands lie in their folded condi tion. A suitable number of guide rollers, such as are shown at s and t in Fig. 2, are provided.

The driving of the various devices described can be effected in any suitable manner, for instance, as shown in Figs. 1 and 2, and described hereinafter.

The conveyer h is driven by gearing constituted by a cam 1 mounted on a shaft 1 and engaging with a bell-crank lever 2 pivoted at 2 said lever being controlled by the action of a spring 3 and having apin-andslot connection 4 with the stem 5 of a toothed sector 6 which is pivoted centrally, as at 5 the teeth of said sector 6 meshing with those of a gear 6 secured to a shaft 7 to.

which are secured the arms of said conveyer.

The gearing for operating the eveners i 0 and g is constituted by a cam 8 mounted on a shaft 8 arranged to vertically reciprocate a table 10 through the medium of a vertical rod 9, against Which table are constantly pressed, by means of springs 11, extensions 12 provided upon the said eveners and passed through guide sleeves 13.

The gearing for driving the beating-up devices is constituted by a cam 14: mounted on a shaft 1 1 said cam acting by means of a vertical rod 15 on a slide 16 secured to the bodies carrying the blades 76 and Z The gearing for operating the drawing cylinder 1' is constituted by a cam 17 mounted on a shaft 17 and arranged to oscillate the pawl 20 of a ratchet wheel 21 secured to the shaft 1' of said cylinder, said pawl being pivoted to one end of a rocking link 19 that is pivoted at its other end to a vertical rod 18 and intermediate its ends to said shaft T The gearing for driving the sprocket wheel or wheels (Z is constituted by a cam 22 mounted on a shaft 22 and oscillating by means of a rod 23 and a link 24: pivoted centrally to the spindle (Z of one of the sprocket wheels (P, the pawl 25 of a ratchet wheel 26 secured to the said spindle (1*. An adjoining gearing for insuring the winding of the bands I) on the winding beam 0 is provided, said gearing preferably comprising a weight 27 suspended from a cord 28 passed over a pulley 29 and wound on the shaft 30 of a gear wheel 30 meshing with a driving pinion 31 keyed to the shaft 0 of the said beam 0.

Each arm of the conveyer h is provided with a terminal hook preferably designed as shown in Figs. 6 to 8, and comprising a lower horizontal branch 32, an upper horizontal branch 33 which has in plan the shape of the letter U, a back vertical branch 34 connecting the said upper and lower branches, and a pair of spring-controlled locking bolts 35. The mounting of the spools (Z on the chain (Z may be effected by means of elastic pincers 36, such as are shown in Figs. 1, 2, 6, 7 and 8, which act on the square trunnions al provided on said spools.

It is obvious that when the width of the machine requires it, the various driving gears may be repeated or duplicated on each side thereof. The rotation of the different cams may be effected in any suitable manner, for instance, by means of chains 37 driving sprocket wheels mounted on said cams and driven from a main driving gearing comprising a belt 38 and a pulley 39.

The operation of the machine is as follows: Assuming that the machine is stopped in the position shown in Figs. 1 and 2, and that the different cams are connected to their gearings so as to rotate in a clockwise direction, if the machine is started,

the conveyer arms it will be brought toward the right with the spool (Z previously seized by their hooks, and the end of each of the threads carried by the said spool will be brought to the right of the reed 2' and laid longitudinally into the V formed by the corresponding band 6. The evener i of the said reed will be raised and the said ends 6 of the threads will be engaged by the grip- .pers. The working continuing, the conveyer will be moved slightly upward, owing to the shape given to the cam 1. The threads will be unwound from the spool 66 in question to an extent corresponding to that of the movement of the conveyer, and

the knife y' will cut them off. The conveyer will then return to its original position and bring back the said spool 45 between the branches of its pincers 36. These operations having been efiected, the cam 22 will move the ratchet wheel 26 which will advance to the extent of one tooth with the sprocket wheel (Z and thus the right hand section of the chain (Z will be caused to advance upward and will carry with it the spool (Z which was previously working, the trunnions (Z of which freely pass the upper horizontal branch 33 of the hooks, owing to their U shape; at the same time, the succeeding spool will be brought into position for its trunnions d to meet the arms of the conveyer and slide along the same until they reach the locking bolts 35 which are permitted to move away from each other by the action of their controlling springs, so as to allow the trunnions d to be gripped by the pincers 36. While this exchange of the spools a? is taking place, the cylinder 1" advances to an extent corresponding to the length of the teeth of its ratchet wheel 21 and drives the bands 6 which were released by the tightening reeds i, 0 and g immedi ately after the action of the knife A certain slack will be produced in the portion of the bands comprised between the cylinder 1" and the winding beam 0, which slack is immediately taken up by the said beam under the action of the weight 27. The bands 6 have advanced in this manner a distance slightly greater than the length of the various piles which are to constitute the velvet, and that portion of each band on which has been deposited the section or piece of thread cut off by the knife j has arrived within reach of the first beating-up device 76 70 which forces the said section into proper longitudinal position in the bottom of the V formed by the band. This is done while a new series of threads corresponding to the succeeding weft of the pattern is being deposited in the succeeding portion of the bands in the above described manner. Afterward, a further advance of the said bands takes place, which brings the threads first cut off to the right of the moistening devicel Z where a part of the priming of the Cingalette is dissolved and the threads are thus caused to adhere to the bands; they are then brought at the exchange of spools, first to the second beating up device m m and then to the second tightening reed 0 So far as the function of the said moistening device is concerned, itmay be stated that Cingalette, which is a starched fabric, as is generally understood, is moistened and softened on passing over the liquid container Z by the vapor produced by or given ofi from the heated liquid. The two branches of the softened Cingalette are then pressed together in the reeds 0 and Q and are simultaneously heated by the action of the devices 0 and Q2, whereupon said branches are again caused to stiffen and hold the piles securely between them. A real pile warp wound around the beam 0 is thus finally obtained, and it is merely necessary to carry the latter on to a suitable loom for carrying out the weaving.

It will be readily understood that in view of the above described construction of the pile Warp, the weaving operation results in the production of a fabric comprising, in addition to the elements which must enter into the carpet to be manufactured finally, the above mentioned bands which latter must be eliminated in the majority of cases. For removing the bands, either physical action such as burning, or chemical action, or mechanical action, may be used, the latter being advantageously carried out by using a cutting pile-raising wire or wires, (the working of which may also alternate wit-h that of one or more non-cutting wires,) and a card suitable for tearing out the elements produced by the cutting of the bands by the cutting wires. It must, moreover, be clearly understood that the invention is not limited to the more particularly described case of its application to the formation of pile warps proper, and that it is to be understood to include also other warps, more particularly those with colored or variable elements. It must be pointed out finally that the invention makes it possible in a general way to place these colored or variable elements one after another and in the form of a continuous band which constitutes a new product capable of being used not only for forming the warps, but also for forming wefts.

We claim as our invention:

1. A process of obtaining a pile warp, consisting in successively introducing series of separate pile threads end to end between the sides of a series of parallel longitudinally-folded bands, so as to form a series of transverse rows of threads, advancing said bands in unison after the format-ion of each row, securing said threads in position in said bands, and winding said bands synchronously upon a beam.

2. A process of obtaining a pile warp, consisting in successively introducing series of separate pile threads of different colors end to end, in the order in which the corresponding colors appear in the pattern to be woven, between the sides of a series of parallel longitudinally-folded bands, so as to form a series of transverse rows of threads, advancing said bands in unison after the formation of each row, securing said threads in position in said bands, and finally removing said bands.

3. A process of obtaining a pile warp consisting in successively introducing series of separate pile threads end to end between the sides of a series of parallel longitudimillyfolded bands of cingalette muslin, so as to form a series of transverse rows of threads, intermittently advancing said bands in unison, moistening said bands to soften the same, subsequently heating said bands and forcing the sides thereof together to cause them to securely hold said threads therebetween, and finally winding said bands upon a beam.

4. A process of producing a warp or weft for use in the manufacture of fabrics which consists in arranging separate threads of various colors that are to constitute the pattern of the fabric longitudinally, one after another, in the order in which the corresponding colors appear in said pattern, to form a continuous band.

5. A process of producing a warp or weft for use in the manufacture of fabrics which consists in securing upon a band the variously-colored threads that are to constitute the pattern of the fabric longitudinally, one after another, in the order in which the corresponding colors appear in said pattern.

6. A warp or weft for use in the manufacture of fabrics comprising a continuous band consisting of a' series of separate threads of various colors arranged longitudinally, one after another, in the order in which the corresponding colors appear in the pattern of the fabric.

7. A warp or weft for use in the manufacture of fabrics comprising a continuous band having secured thereon a series of variouslycolored threads arranged longitudinally, one after another, in the order in which the corresponding colors appear in the pattern of the fabric.

8. A warp or weft for use in the manufacture of fabrics comprising a continuous longitudinally-folded band having secured between the sides thereof a series of variously-colored threads arranged longitudinally, one after another, in the order in which the corresponding colors appear in the pattern of the fabric.

9. A process of producing a warp or weft for use in the manufacture of fabrics consisting in securing upon a band the variously-colored threads that are to constitute the pattern of the fabric longitudinally, one after another, in the order in which the corresponding colors appear in said pattern, and in subsequently removing said band.

In testimony whereof we have signed our names to this specification in the presence of two subscribing witnesses.

PAUL SABONADIER. ETIENNE DEAUBONNE. lVitnesses H. C. CoxE, ARMAND MARX.

Copies of this patent may be obtained for five cents each, by addressing the Commissioner of Patents, Washington, D. G. 

